System and method for dynamically simulating process and value stream maps

ABSTRACT

A computer readable medium comprising instructions which when executed by a computer system causes the computer to implement a method for dynamically improving a process flow is provided. For a plurality of cells, which define activities within the process flow and are characterized by a corresponding plurality of productivity data elements, the method triggers a state engine to simulate the process flow, with the state engine configured to manage all operations rules related to the process flow, and determines at least one process improvement. The method further identifies productivity data elements that correspond to the at least one process improvement, and dynamically modifies the identified productivity data elements to improve the process flow.

FIELD

The present embodiments relate, in general, to process flows and, moreparticularly, to a system and method for dynamically simulating processand value stream maps.

BACKGROUND

With today's emphasis on “lean implementation” in business environments,manufacturing and service, companies seek to acquire tools thateffectively identify problems affecting productivity and updatework-in-progress process flows with newly inserted tasks. A basicphilosophy of the lean implementation into a process flow is to targetinefficiency and to improve economical goals, which is accomplished byfocusing on determining production times that meet or exceed customerrequirements. Initiatives of lean implementations typically begin with adevelopment of a value stream map of an operation. However, the valuestream map does not take into consideration a dynamic aspect of theoperation and a product mix that may be in production at differenttimes.

Six Sigma is a method, based on standard deviations, used to analyze andidentify variations in process flows to provide productivityimprovements. As such, some companies have integrated aspects of thesix-sigma and lean tools to improve productivity in the manufacturingand service environments. However, when process map studies andsimulations are required due to changes in process constraints, furtheroff-line actions have to be undertaken such as building, verifying andvalidating simulation models for experimentation of improvements. Theseactions thus lack a dynamic aspect of integrations or modifications inmodel simulations.

Accordingly, a system and method is desired that can integrate andcombine varied analytical and implementation tools to dynamically build,simulate and analyze processes subjected to any applicable conditionsand scenarios to provide productivity improvements.

BRIEF SUMMARY

The present invention is defined by the appended claims. Thisdescription summarizes some aspects of the present embodiments andshould not be used to limit the claims.

A computer readable medium comprising instructions which when executedby a computer system causes the computer to implement a method fordynamically improving a process flow is provided. For a plurality ofcells, which define activities within the process flow and arecharacterized by a corresponding plurality of productivity parameters,the method triggers a state engine to simulate the process flow, withthe state engine configured to manage all operations rules related tothe process flow, and determines at least one process improvement. Themethod further identifies productivity parameters that correspond to theat least one process improvement, and dynamically modifies theidentified productivity parameters to improve the process flow.

A computer readable medium comprising instructions which when executedby a computer system causes the computer to implement a method forcreating a dynamic value stream map is provided. For a plurality ofcells defining activities within the process flow and characterized by acorresponding plurality of productivity parameters, the methodidentifies value stream metrics, which corresponding to the plurality ofcells and to interrelationships between the plurality of cells. Themethod further triggers a state engine to simulate the value stream map,the state engine configured to manage all operations rules related tothe value stream map, and dynamically update the value stream metricsduring the simulation of the value stream map and analyze a value streammap performance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a functional diagram of a process simulation systemin accordance with the invention;

FIG. 2 is a flow chart illustrating a method for dynamically improving aprocess flow;

FIG. 3 is a flow chart illustrating a method for dynamically creating avalue stream map;

FIG. 4 is a graphical display illustrating a simulation of a processmap;

FIG. 5 is a graphical display illustrating a value stream mapcorresponding to the process map of FIG. 4; and

FIG. 6 is a block diagram illustrating the process simulation system ofFIG. 1 with a plurality of input data sources and a plurality of outputtasks; and

FIG. 7 is a block diagram illustrating potential industry and businessapplications of the simulation system.

Illustrative and exemplary embodiments of the invention are described infurther detail below with reference to and in conjunction with thefigures.

In the drawings, identical reference numbers identify identical orsubstantially similar elements or acts. To easily identify thediscussion of any particular element or act, the most significant digitor digits in a reference number refer to the Figure number in which thatelement is first introduced.

A portion of this disclosure contains material to which a claim forcopyright is made. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure(including Figures), as it appears in the Patent and Trademark Officepatent file or records, but reserves all other copyright rightswhatsoever.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention is defined by the appended claims. Thisdescription summarizes some aspects of the present embodiments andshould not be used to limit the claims.

While the present invention may be embodied in various forms, there isshown in the drawings and will hereinafter be described some exemplaryand non-limiting embodiments, with the understanding that the presentdisclosure is to be considered an exemplification of the invention andis not intended to limit the invention to the specific embodimentsillustrated.

In this application, the use of the disjunctive is intended to includethe conjunctive. The use of definite or indefinite articles is notintended to indicate cardinality. In particular, a reference to “the”object or “a and an” object is intended to denote also one of a possibleplurality of such objects.

Turning now to the drawings, and particularly to FIG. 1, a functionaldiagram of a process simulation system embodying the principles of thepresent invention is illustrated and generally designated at 10. In thepresent process simulation system 10, a simulation or state engine 11communicates with a data store 12, data access adaptors 13 to exchangeboth internal and external data, respectively, and a Legacy host 14 thatincludes or interfaces with external applications.

With regard to a user presentation, simulation system 10 includes a userinterface to display and manage data, provide static and dynamic viewsof process flows, and control simulation runs. The user interface 15 isconnected to the simulation engine 11 to initiate, pause and terminatesimulation runs, and to the data store 12 to upload and update processmodel data. The user interface 15 can reside on or be connected todesktop and portable PC options 16, thin clients 17 via web servers, andportable devices 18 via wireless networks.

The data store 12 represents a working area for data transfers betweencomponents of the simulation model. The data store 12 restores data tothe simulation engine 11 directly or via an event data store 12 a, whilethe later externalizes it back. A record of each operation or activitycompleted during a simulation run by the simulation engine 11 may bestored in the data store 12, thereby providing a complete audit trail ofall essential operations or activities performed during simulation runs.

The event data store 12 a represents a working area for data storage andtransfers during simulation runtime. This event data store 12 a can be arelational database, which passes to and receives data from thesimulation engine 11, the user interface 15 and other components of thesimulation system. Alternately, the event data store 12 a may resideindependently of the data store 12, while remaining coupled to eachother.

Functionally, the simulation engine 11 manages all the rules related toa process flow during a corresponding simulation run. Moreover, any rulechanges made via the user interface 15, data store 12 or externalinterfaces (Legacy Host) 14 are automatically captured and implementedby the simulation engine 11 during a simulation run. Once a simulationrun is stopped or cancelled, the simulation engine 11 may no longer beaware of the process flow until another simulation trigger occurs. Thesimulation engine 11 supports global process operations inclusive ofaccessing data, and managing that data for access by individualcomponents or applications. Simulations of the process flow canrepresent simple and complex operations, whose metadata are defined bycorresponding rules by which the simulation engine 11 will execute them.

Functionally, the simulation engine 11 is triggered to begin a processflow simulation. The rules of operations of the process flow are cachedupon startup or a first execution of the process flow and represent thelife of the process flow. Thereafter, the simulation engine 11 performsa flow of operations until it encounters a task or trigger that requeststhe process flow to pause, terminate or resume with altered rules ofoperations. These rules of operations include parameters or variables ofcells and interrelationships between these cells that define activitieswithin the process flow. For the sake of simplicity, hereafter thesimulation system 10 will be referred to as a simulation tool, andcomponents of the simulation system 10 will be individually discussedwhen appropriate.

In manufacturing, production, business or office systems, workpieces,people or goods flow through stages or cells that may be separated bytransportation transitions (carriers) or storage spaces for temporarystorage, referred to herein as buffers. Each cell comprises one or morecell operations, a robotically or computer generated task, or a taskperformed by human operation such as assembly or machining. Buffers canbe either parallel or crossover. The crossover type is capable ofstoring and cross-feeding workpieces from any upstream cell to anydownstream cell, and the parallel type can only store and feedworkpieces from a single designated upstream cell to designateddownstream cells. Since each cell has its own cycle time, frequency ofmachine breakdown, and time required to repair, and each buffer has itsown capacity, the flow of the system can be interrupted, starved, orblocked by any mismatches between cells.

One problem is to improve a performance of such a system, but thisperformance is governed by a combination of interrelations between cellsand buffers, which are characterized by respective parameters. Modifyingone cell or one buffer without considering the existinginterrelationship to the other cells or buffers may lead to minimum orno improvement in performance. Thus, the targeted solution lies infinding a dynamic approach to determine a combination of cell and bufferparameters under which the system meets a desired performance. Some ofthese parameters are, of course, more controllable than others. So thedegree of design freedom of the system may be limited and constraintsmay exist even on the controllable parameters.

As such, a thorough understanding of the behavior of the system can beacquired by creating an accurate process model that reflects theactivities of the cells, and of the buffers. A simulation of the processmodel provides a process map, which is generically a hierarchicalprocedure for displaying and illustrating how a product or transactionis processed. The process map comprises a stream of cell activities thattransforms an input or a set of inputs into a pre-determined set ofoutputs, and provides an understanding of the interaction of activitiesand causes during the process flow. Thus, a dynamic process map may beused to determine a combination of parameters under which the processflow of the system is modified to reach the targeted or best possibleperformance.

Given a manufacturing, production, business or office process, and usingthe simulation tool 10, a model of the process is initially built orconfigured with stored data of cells, buffers, resources and otherrelated entities based on a determined initial or current state of theprocess. Alternately, the process model may be configured based on auser entry, via the user interface 15, while defining respectivelocation of the cells, buffers, including their respective activitiesand parameters, as well as related resources and entities. Therespective location of the cells and buffers in the process model maysubstantially determine a routing of the manufactured objects orworkpieces through the model. Alternately, the process model may beautomatically built and configured based on routing tables or other flowdefinition methods. The routing tables may be accessed or retrieved fromthe data store 12 or from external applications 14. Thus, the buildingor configuration of the process model may be executed or performedwithout any software coding created internally by the simulation tool orexternally by the user. Once configured, the process model is loaded tothe data store 12 as the default model for the process.

In FIG. 2, a flow chart illustrates a method for dynamically improving aprocess flow. To simulate the process flow, the simulation engine 11 istriggered via the user interface 11 or external events, at step 20.Subsequently, the simulation engine 11 acquires or caches all the rulesrelated to the process flow from the data store and other contributingcomponents of the simulation model. During the simulation, thesimulation engine 11 provides run time data to the user interface 15 todisplay dynamically the resulting process map, and to the event datastore 12 for storage and tracking purposes. Accordingly, the process mapmay animate and display custom and simulation properties of the objects,resources, and other entities dynamically during the simulation run, andat the end of the simulation run.

During this simulation run, the user may wish to determine animprovement to the process flow to mitigate a problem with one orseveral of the cells or buffers, for example, or to play “what if”scenarios, at step 22. Based on the dynamic display of the process mapor on report, the user may identify productivity parameters thatcorrespond to the problem or the “what if” scenario, at step 24. Theuser may then modify at least one of the identified parameters on thefly while the simulation progresses, at step 26. Such parametermodification is recognized dynamically by the simulation tool 10, andthe modified parameters are incorporated in the event data store 11 forthe remainder of the simulation or until the next parametermodification. The dynamic incorporation of the modified parametersenable the simulation tool 10 to provide a corresponding dynamic processmap to be evaluated and analyzed by the user, at step 28. Everymodification or change of the process model, such as parameter orresource modifications, is captured as a departure from the currentversion of the process model, and the simulation tool 10 dynamicallydesignates or uses the new version of the process model to producedynamically a corresponding process map. As such, the simulation tool 10can track and record a history of changes done to the process model.

Further, as departures from the current version of the process model arestored and used to produce corresponding process maps, the simulationtool 10 can simulate, and analyze multiple scenarios simultaneously.Additionally, the simulation tool 10 can be configured to modify thecurrent simulation run in order to mitigate a simulation-run violationof limits or thresholds imposed on the parameters, for example, or toimprove and optimize the process performance. The simulation tool 10 canfurther dynamically change routing, selection, cycle times, and allother constraints and properties during the simulation run based onpredetermined conditions, scenarios related to scheduling of resources,and so forth.

The process improvement may relate to mitigating a bottleneck, a delay,a scheduling problem, or reducing operating costs. The processimprovement may also correspond to a new routing of the process flow,cycle times of each of the plurality of cells, input resources, andoutput requirements of the process flow.

In regard to routing of the process flow, the simulation tool 10 canalso import or load external routing tables from external applications14 dynamically and update the routing of objects, resources, and otherentities based on the imported routing table. The imported routing tablecan further be changed dynamically during the simulation run by the useror by external applications 14. The modified routing can be reloaded orre-synchronized with the process model with direct impact on theon-going simulation run. Moreover, the simulation tool 10 candynamically interface with an external application 14 and export orimport data at any time during the simulation run. In addition toimported routing tables, the imported data can represent modifiedparameters, new cells, and so forth.

Just as each cell comprises one or more cell operations within theprocess model, the cell may further comprise a plurality of sub-cells,and a process flow of these sub-cells may also represent a correspondingsubprocess of the process. These sub-cells thus determine correspondingactivities within the sub-processes, and are characterized by aplurality of productivity sub-parameters. As such, in order to improveor modify the cell performance, the user may wish to determine animprovement to the sub-process flow by mitigating a problem with one orseveral of the sub-cells or sub-buffers, for example, or to play “whatif” scenarios at the sub-cell layer. Based on the dynamic display of thesub-process map, the user may identify productivity sub-parameters thatcorrespond to the problem or the “what if” scenario. The user may thenmodify at least one of the identified sub-parameters on the fly whilethe simulation progresses. Such sub-parameter modification is recognizeddynamically by the simulation tool 10, and the modified sub-parametersare incorporated in the event data store for the remainder of thesimulation. Every modification or change of the sub-process model, suchas sub-parameter or resource modifications, is captured as a departurefrom the current version of the sub-process model, and the simulationtool 10 dynamically designates or uses the new version of thesub-process model to produce dynamically a corresponding sub-processmap. As such, the simulation tool 10 can track and record a history ofchanges done to the sub-process model.

As sub-processes may determine a layering of the process model, theprocess model can be layered, hierarchically or otherwise, so as toinclude or contain a number of layers that may be interconnected. Theselayers may represent sub-process models relating to cells of the processmodel, or multiple process models linked to one another through processlinks. These process links may be buffers, common cells, or otherconnecting process models. In this layered arrangement, the process mapcan be simulated for the overall process model, for an individual ormultiple sub-processes (layers, for example) simultaneously.

In addition to the process flow, a static value stream encompasses allthe steps (both value added and non-value added) in the process thathelps bring a product (object or workpiece) or service through theprocess flow and essential to producing the product or service. A valuestream map enables an understanding of flow of information as productsor services make their way through the value stream. The value streammap is typically configured to gather and display a broad range ofinformation, and is used at a broad level, i.e. from the receiving ofraw material to the delivery of finished products. The value stream mapmay be used to identify where to focus future projects, subprojects,and/or Kaizan events. Thus, the value stream map takes into account notonly the activity or journey of the product or service, but also themanagement and information systems that support the process flow. Thesecharacteristics of the value stream map are substantially helpful togain insight into potential efficiency improvements in addition to theprocess flow, thereby helpful when aiming to reduce cell cycle time forexample.

However, the value stream map does not take into consideration a dynamicaspect of the process flow or operation and a product mix that may be inproduction at different times. As such, a dynamic value stream mappingis provided to simulate, analyze and evaluate the value stream whensubjected to any applicable conditions and scenarios.

As discussed above in regard to the process mapping, given amanufacturing, production, business or office process, and using thesimulation tool 10, a model of the process is initially built orconfigured with data of cells, buffers, resources and other relatedentities, such as value stream metrics corresponding to the cells and tointerrelationships between the cells.

For each of the cells in the process, the corresponding value streammetrics can represent value added time (VAT), non-VAT, efficiency, takttime, objects completed, objects in progress, capacity, downtime, set-upand change over, load time, unload time, buffer size, lead time, and soforth.

In FIG. 3, a flow chart illustrates a method for dynamically creating avalue stream map. To create a dynamic value stream map, the simulationengine is triggered via the user interface 15 or by external events, atstep 30. At the start or during this simulation run, the user may wishto identify or select all or a subset of the available value streammetrics that correspond to the cells of the process flow and tointerrelationships between these cells, at step 32. During thesimulation of the value stream map, at step 34, the selected valuestream metrics are evaluated and dynamically updated at step 36, therebycreating the dynamic value stream mapping.

Moreover, in order to analyze and evaluate the value stream whensubjected to any applicable conditions and “what if” scenarios, the usermay identify a set of corresponding value stream metrics. The user orexternal applications 14 may then modify at least one of thecorresponding value stream metrics on the fly while the simulationprogresses. Such value stream metric modification is recognizeddynamically by the simulation tool 10, and the modified value streammetrics are incorporated in the event data store for the remainder ofthe simulation or until the next value metrics modification. Everymodification or change of the value stream metrics is captured as adeparture from the current version of the value stream, and thesimulation tool 10 dynamically designates or uses the new version of thevalue stream to create dynamically a corresponding value stream map. Assuch, the simulation tool 10 can track and record a history of states ofthe value stream maps.

Further, as different versions, departures from the current version, ofthe value stream are stored and used to produce corresponding valuestream maps, and the simulation tool 10 can simulate simultaneouslythese different value stream maps.

As stated earlier, cells may include sub-cells that determine activitieswithin corresponding sub-processes, and are characterized by a pluralityof productivity sub-parameters. In addition, value stream metrics may beidentified that correspond to the sub-cells and to interrelationshipsbetween the sub-cells. During the simulation, selected value streammetrics of the sub-cells or interrelationship between the sub-cells areevaluated and dynamically updated, thereby creating the correspondingdynamic value stream mapping.

Moreover, due the potential layered arrangement of the process model,the dynamic value stream map can be simulated for the overall processmodel, for an individual or for multiple sub-processes (layers, forexample) simultaneously.

Due the dynamic importation and exportation of data, routing tables andvalue stream metrics of cells, for example, prior to or during a processsimulation, the value stream map may be useful to predict or forecastfuture value stream maps. Such imported value stream metrics maycorrespond to work in progress (WIP) or forecasted data. The simulatedvalue stream map may dynamically detect future potential bottlenecks,delays, and scheduling problems.

This dynamic value stream map can validate change within the Leanconstraints. Further, based on the interaction between the value streammaps, minimum requirements may be set for the Six Sigma initiatives.

As the simulation engine 11 manages all the rules related to the processflow during a corresponding simulation run, and supports the simulationof the dynamic process map, and the static and dynamic value streammaps, all of the data used and produced by the simulation engine 10 canbe provided dynamically and interactively between their respectivesimulations.

As discussed above, the process model may be configured and built basedon a user entry, via the user interface of the simulation tool, whiledefining respective location of the cells, buffers, including theirrespective activities, parameters, and value stream metrics, as well asrelated resources and entities. As shown in FIG. 1, the user interface15 communicates directly to the simulation engine 10. With that, a userusing a graphical interface 19 can build the process model.

Graphically, the user can determine process graphic units (cells,objects, and the like) to be monitored or controlled and a layout of theprocess, which may be imported from a CAD layout, then create flowconnectors (buffers and the like) between the cells to determinedirections and constraints (buffers) of the process flow. To representthe process units and connectors, stored graphical icons can beretrieved from the data store 12, or customized icons can be imported.Alternately, the simulation tool 10 can enable the user to interface tovisual basic (VB) scripts or code for additional model customization, asshown in FIG. 4.

Once the process model is built, the user can add, graphically or viadata import, other process constraints or parameters, such as cycletimes, resource requirements, change over, mean time between failures(MTBF) and mean time between repairs (MTBR), and so forth, to theprocess. In a situation, where the user does not determine or set someconstraints or parameters, the simulation tool 10 can define defaultvalues for these constraints and parameters. All graphical units andconnectors created are dynamically communicated, along with theirconstraints and parameters, to the simulation engine 11, andsubsequently to the data store 12 to be available to other components ofthe simulation tool 10. Additionally, any process model, in part or inwhole, can be copied and pasted onto any another process model. Suchgraphical actions on and between the process models preserves allproperties of the copied, and pasted process model parts. Further, sincemodel processes can include a number of layers that may or may not beinterconnected. These layers may represent sub-process models relatingto cells of the process model, or multiple process models linked to oneanother through process links. If a layer needs to be duplicated in thesame model or across different process models, this layer may be copiedor pasted as one unit in the same model or across different models.

After starting or triggering a simulation run, all animations of theprocess are generated by the simulation tool 10 and provided dynamicallyto the graphical interface 19 via the user interface 15. Theseanimations correspond to the behavior or progress of the cells, objects,buffers, as well as data, during the simulation run. As such, thesimulation tool 10 can generate and provide via graphical interface 19 apath for every object, resource, or any traveling entity, during thesimulation run and identify lean values (non-value added time, valueadded time, transition time, processing time, and others) per object,path, and flows.

Since the simulation engine 10 is in communication with the event datastore 11 during the simulation run, the user can request a display inreal time of any statistical data relating to the process, connections,or objects, as well as a graph of any tracked statistical data as itchanges through time during the simulation run and after the simulationrun completes. The user can also request analysis reports detailingpotential problems in the simulated model based on the predeterminedconstraints. Information reports, that detail the process modelproperties, are configured to contain links to dynamically modify unitor connection properties without the need to switch to the graphicalmodel. The reports, statistical and informational, may be customized bythe user, and generated during or after the simulation to be used asguides to help improve and optimize the flow.

In support of the dynamic process and value stream maps discussed above,the user can graphically modify the simulation model during thesimulation run, and make changes to the routing of the process, cycletimes, resource requirements, and all other constraints and propertiesof the model. The user can trigger a pause to the simulation run, thenresume without any resetting or loss of the data. However, the user caninitiate the data collection and analysis to be reset as many times asneeded during the simulation run while maintaining the model behaviorand object and resource positions.

The user may simulate the process flow by triggering the simulationengine from the graphical interface 19. During the simulation, thesimulation tool 10 provides run time data to display dynamically theresulting process map. Accordingly, the process map is graphicallyanimated displaying custom and simulation properties of the objects,resources, and other entities dynamically during the simulation run, andat the end of the simulation run.

During this simulation run and using the dynamic display of the processmap, the user may identify productivity parameters that correspond to aprocess problem or to “what if” scenarios. The user may then recall orhighlight to modify at least one of the identified parameters on the flywhile the simulation progresses. Such parameter modification isrecognized dynamically by the simulation tool 10, and the modifiedparameters are incorporated in the event data store 19 for the remainderof the simulation. Since every modification or change of the processmodel is captured as a departure from the current version of the processmodel, the user may opt to simultaneously simulate more than one dynamicprocess map, and display them simultaneously on the graphical interface.As such, the user can run several versions or scenarios of the processfor educational and analytical comparisons.

Similarly, the user can create dynamic value stream maps of the processby dynamically modifying or altering targeted value stream metrics. Assuch, a number of versions or scenarios of value stream maps can besimultaneously simulated as well as displayed graphically. The valuestream map can be overlaid over a graphical layout of the process, as animage file or a CAD drawing, as shown in FIG. 5. The dynamic valuestream is updated in real-time based on the simulation progress and theupdates are displayed on the CAD layout or image file. Moreover, theprocess map and value stream map can be hierarchically layered whereeach map may contain a number of layers. As such, the user may opt toselect for viewing and tracking any combination of layers of both theprocess and value stream maps.

As discussed above, dynamic process and value stream maps are configuredto exchange data during the simulation run. Accordingly, the user maybenefit from creating a dynamic process map to view and analyze theresulting impact on the corresponding value stream map. Vice-versa, bycreating a dynamic value stream map, the user can view and analyze theresulting impact on the dynamic process map.

As mentioned above, the simulation tool 10 can include data connectivityto desktop and portable personal computers 16, as well as to thinclients 18 via web servers and to portable devices 17 via wirelessnetworks. Thus, the user may dynamically import real time data to trackoperations within an on-going process in a number of ways. The importeddata can originate via updates from external databases, files, radiofrequency identification (RFID) devices, and global positioning (GPS)devices, among others.

The tracking can be applied or performed on objects, resources,carriers, and all animated entities within the simulation data. Trackingdata may be used to perform predictability and forecasting analysis onthe process to show the future state of the process and how it mightprogress through time. Each tracked product or object can be queried forposition, history, and statistical data during the tracking and/orsimulation and forecasting data. As the simulation tool 10 feedsdynamically all run time data to the user interface 15, the tracking canbe displayed or animated in real time at a substantially exact locationof the tracked object on the CAD layout or image file with properscaling. The tracking data and corresponding analysis can be stored forlater retrieval/replay of the process. The collected tracked data can beused as an initial state of the process to simulate the dynamic processmap, and create dynamic value stream map to predict problems and provideproactively corresponding remedies or solutions. The statistical datagenerated by the tracking may be used to generate a correspondingdynamic value stream map.

As stated above, the simulation tool 10 can be connected to portablecomputers 16, such as PDAs, wireless devices, and wireless notebooks.The real time process data, including and not limited to processproperties, model flow, resources, carriers, time studies, and modelconstraints, can be captured or taken on the field from operations ofthe process via the portable devices then imported in the simulationtool without the need for a third party software.

The user can export the process model to the PDA, and then walk thecorresponding real layout of the process in a plant or an office toinput parameters directly onto the PDA 16. The modified or newparameters are then imported into the simulation tool 10, i.e. to theprocess flow and the process and value stream maps. Once the data isimported, the user may initiate the simulation tool 10 or otherappropriate applications to perform time study analysis, flow analysis,and so forth. Alternately, the user may collect real time parameterswithout having a priori the process model on the portable device.

The graphical interface 19 may also offer three dimensional (3D) viewsor the process model based on the built or configured 2D process model.The user may display simultaneously both 2D and 3D views of the processor of a selected layer or layers of the process or switch between thetwo views. Further, the user may display background images or graphics(CAD or image file) in 3D views, and export the 3D views to the 2D viewsbased on the flow settings. Moreover, the user may display the dynamicvalue stream map in 3D views, dynamically update the content of thevalue stream map in 3D views, and modify the process map and/or thevalue stream map in 3D views during the simulation run.

In view of the above discussion and as shown in FIG. 6, the proposedsimulation system 10 accomplishes imports of process data via amulti-channel data capture sub-system, such as ordering and schedulingdatabases or Excel sources 61 a, enterprise resource planning (ERP) andmanufacturing resource planning (MRP) and Tracking databases 61 b,process flow and flow constraints 61 c, and resources, productions,carriers 61 d, and so forth. In return, the simulation system 10provides a spectrum of analytical, statistical and informative tools,such as flow analysis 62 a, real time tracking 62 b, process improvement62 c, Lean and Six Sigma statistics 62 d, static and dynamic valuestream maps 62 e, and forecasting 62 g.

In FIG. 7, a block diagram illustrates an example of the extendedbusiness application area offered by the proposed simulation system 10.Such extended business area runs the gamut of process orientedbusinesses, such as but not limited to banking industry 7 a, automation7 b, assembly 7 c, manufacturing 7 d, logistics and transportation 7 e,job shop operations 7 f, retail industry 7 g, call centers and serviceindustry 7 h, warehousing 7 i, and healthcare 7 j.

It is therefore intended that the foregoing detailed description beregarded as illustrative rather than limiting, and that it be understoodthat it is the following claims, including all equivalents, that areintended to define the spirit and scope of this invention.

1. A computer readable medium comprising instructions executed by acomputer system to implement a method for dynamically improving aprocess flow, the method comprising: identifying a plurality of cells ofthe process flow, which are each characterized by a correspondingplurality of productivity parameters; triggering a state engine tosimulate the process flow, the state engine configured to manage theplurality of productivity parameters and operations rules related to theprocess flow; determining at least one process improvement; identifyingat least one productivity parameter that corresponds to the at least oneprocess improvement; and providing on the fly an adjustment of the atleast one identified productivity parameter to the state engine todynamically modify the simulation of the process flow.
 2. The computerreadable medium comprising instructions to implement a method fordynamically modifying a process flow of claim 1, wherein the at leastone improvement comprises mitigating a bottleneck, a delay, and/or ascheduling conflict.
 3. The computer readable medium comprisinginstructions to implement a method for dynamically modifying a processflow of claim 1, wherein the process flow comprises a manufacturingprocess and the at least one improvement comprises to reducing operatingcosts of the manufacturing process.
 4. The computer readable mediumcomprising instructions to implement a method for dynamically modifyinga process flow of claim 1, wherein the at least one productivityparameter is one of routings of the process flow, cycle times of each ofthe plurality of cells, input resources, and output requirements of theprocess flow.
 5. The computer readable medium comprising instructions toimplement a method for dynamically modifying a process flow of claim 1,wherein the step of triggering the state engine further comprises:pausing the state engine at a determined instant; modifying theidentified productivity parameters; and retriggering the state engine.6. The computer readable medium comprising instructions to implement amethod for dynamically modifying a process flow of claim 1, the methodfurther comprising: generating custom reports during the simulation ofthe process flow.
 7. The computer readable medium comprisinginstructions to implement a method for dynamically modifying a processflow of claim 1, the method further comprising: communicating simulationdata to a graphical user interface; and dynamically displayingsimulation data over a graphical representation of the process flow. 8.The computer readable medium comprising instructions to implement amethod for dynamically modifying a process flow of claim 7, wherein thedisplayed simulation data represents constraints and bottlenecks.
 9. Thecomputer readable medium comprising instructions to implement a methodfor dynamically modifying a process flow of claim 7, wherein thegraphical representation is a three dimensional representation.
 10. Thecomputer readable medium comprising instructions to implement a methodfor dynamically modifying a process flow of claim 1, the method furthercomprising: importing data corresponding to the process flow; andproviding on the fly imported data to the state engine to dynamicallymodify the simulation of the process flow.
 11. The computer readablemedium comprising instructions to implement a method for dynamicallymodifying a process flow of claim 10, wherein the imported datacomprises modified productivity parameters.
 12. The computer readablemedium comprising instructions to implement a method for dynamicallymodifying a process flow of claim 10, wherein the imported datacomprises at least one new cell.
 13. The computer readable mediumcomprising instructions to implement a method for dynamically modifyinga process flow of claim 10, wherein the imported data comprises modifiedrouting tables of the process flow.
 14. The computer readable mediumcomprising instructions to implement a method for dynamically modifyinga process flow of claim 10, wherein the step of importing data enablesforecasting bottlenecks, delays, and/or scheduling problems.
 15. Thecomputer readable medium comprising instructions to implement a methodfor dynamically modifying a process flow of claim 1, the method furthercomprising: dynamically storing simulation data provided by the stateengine in a database.
 16. The computer readable medium comprisinginstructions to implement a method for dynamically modifying a processflow of claim 15, the method further comprising: dynamically displayingstored simulation data for a post-simulation analysis.
 17. The computerreadable medium comprising instructions to implement a method fordynamically modifying a process flow of claim 15, wherein thedynamically stored data enables a tracking of an object navigating theprocess flow.
 18. The computer readable medium comprising instructionsto implement a method for dynamically modifying a process flow of claim17, wherein the tracking of the object enables a dynamic allocation ofthe tracked object.
 19. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 17, wherein the graphical representation and position ofthe tracked object is provided dynamically during the simulation. 20.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 17, wherein thegraphical representation and position of the tracked object is provideddynamically after the simulation.
 21. A computer readable mediumcomprising instructions executed by a computer system to implement amethod for dynamically improving a process flow, the method comprising:identifying a sub-process, the sub-process comprising a plurality ofsub-cells, the plurality of sub-cells defining activities within thesub-process flow and characterized by a corresponding plurality ofproductivity parameters; triggering a state engine to simulate thesub-process flow, the state engine configured to manage the plurality ofproductivity parameters and operations rules related to the sub-processflow; determining at least one sub-process improvement; identifyingproductivity at least one parameter that corresponds to the at least onesub-process improvement; and providing on the fly an adjustment of theat least one identified productivity parameter to the state engine todynamically modify the simulation of the sub-process flow.
 22. Acomputer readable medium comprising instructions executed by a computersystem to implement a method for creating a dynamic value stream map ofa process flow, the value stream map represented by a plurality of valuestream metrics corresponding to a plurality of cells of the process andto interrelationships between the plurality of cells, the methodcomprising: triggering a state engine to simulate the value stream map,the state engine configured to manage the plurality of value streammetrics and operations rules related the value stream map; evaluatingthe value stream metrics in the state engine during the simulation ofthe value stream map; and updating on the fly the value stream map withthe evaluated value stream metrics to provide a dynamic value streammap.
 23. The computer readable medium comprising instructions toimplement a method for creating a dynamic value stream map of claim 22,the method further comprising: analyzing the dynamically updated valuestream metrics to evaluate a performance of the value stream map. 24.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 22, wherein thevalue stream metrics are at least one of value added time (VAT),non-VAT, efficiency, take time, objects completed, objects in progress,capacity, downtime, set-up and change over, load time, unload time,buffer size, and lead time.
 25. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 22, wherein the value stream metrics are customized. 26.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 23, furthercomprising: determining at least one dynamic value stream mapimprovement; identifying at least one value stream metric thatcorresponds to the at least one value stream improvement; and providingon the fly an adjustment of the at least one identified value streammetric to the state engine to dynamically modify the simulation of thevalue stream map.
 27. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 22, the method further comprising: dynamically storing datacorresponding to the evaluated value stream metrics in a database. 28.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 27, the methodfurther comprising: dynamically displaying stored simulation data for apost-simulation analysis.
 29. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 22, further comprising: communicating simulated valuestream metrics data to a graphical user interface; and dynamicallydisplaying value stream metrics data over a graphical representation ofthe value stream map.
 30. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 29, wherein the graphical representation is a threedimensional representation.
 31. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 22, the method further comprising: exchanging data betweenthe process flow and the dynamic value stream map.
 32. The computerreadable medium comprising instructions to implement a method forcreating a dynamic value stream map of claim 22, wherein one of thevalue stream metrics corresponds to tracking data of an object.
 33. Thecomputer readable medium comprising instructions to implement a methodfor creating a dynamic value stream map of claim 32, wherein thetracking data enables a dynamic allocation of the tracked object. 34.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 33, wherein agraphical representation and position of the tracked object is provideddynamically during the simulation of the dynamic value stream map. 35.The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 34, wherein thegraphical representation and position of the tracked object is provideddynamically after the simulation using the corresponding stored data.36. The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 22, the methodcomprising: providing on the fly new data corresponding to the valuestream metrics to the state engine thereby dynamically modifying thesimulation of the value stream map.
 37. The computer readable mediumcomprising instructions to implement a method for creating a dynamicvalue stream map of claim 36, wherein the data is provided by externalapplications.
 38. The computer readable medium comprising instructionsto implement a method for creating a dynamic value stream map of claim36, wherein the provided data corresponds to cell and/or buffer data.39. The computer readable medium comprising instructions to implement amethod for creating a dynamic value stream map of claim 36, wherein theprovided data corresponds to alternate routing tables of the processflow or process definition methods.
 40. A computer readable mediumcomprising instructions executed by a computer system to implement amethod for creating a dynamic value stream map of a sub-process flow,the value stream map represented by a plurality of value stream metricscorresponding to a plurality of sub-cells of the process and tointerrelationships between the plurality of sub-cells, the methodcomprising: triggering a state engine to simulate the value stream map,the state engine configured to manage the plurality of value streammetrics and operations rules related to the value stream map;dynamically evaluating the value stream metrics in the state engineduring the simulation of the value stream map; and updating on the flythe value stream map with the evaluated value stream metrics to providea dynamic value stream map.
 41. The computer readable medium comprisinginstructions to implement a method for creating a dynamic value streammap of claim 40, the method further comprising: analyzing thedynamically evaluated value stream metrics to evaluate a performance ofthe value stream map.
 42. A computer readable medium comprisinginstructions executed by a computer system to implement a method fordynamically modifying a flow of a process, the process characterized bya plurality of cells, which are each characterized by a correspondingplurality of productivity parameters, and interrelationships between theplurality of cells, the method comprising: triggering a state engine tosimulate the process flow, the state engine configured to manage theplurality of productivity parameters and operations rules related to theprocess flow; and providing on the fly process data to the state engine,thereby dynamically modifying the simulation of the process flow. 43.The computer readable medium comprising instructions to implement amethod for dynamically modifying the process flow of claim 42, whereinthe provided data is provided by external applications.
 44. The computerreadable medium comprising instructions to implement a method fordynamically modifying the process flow of claim 42, wherein the provideddata corresponds to cell and/or buffer data.
 45. The computer readablemedium comprising instructions to implement a method for dynamicallymodifying a process flow of claim 42, wherein the provided datacorresponds to alternate routing tables of the process flow processdefinition methods.
 46. A computer readable medium comprisinginstructions executed by a computer system to implement a method fordynamically creating a process flow, the method comprising: triggering astate engine, the state engine configured to manage all operations rulesrelated to the process flow; providing on the fly process data to thestate engine, the process data corresponding to a plurality of cells,which are each characterized by a corresponding plurality ofproductivity parameters, and interrelationships between the plurality ofcells, thereby incorporating the provided data to dynamically create theprocess flow.
 47. The computer readable medium comprising instructionsto implement a method for dynamically creating the process flow of claim46, wherein the provided data is provided by external applications. 48.The computer readable medium comprising instructions to implement amethod for dynamically creating the process flow of claim 47, whereinthe provided data corresponds to cell and/or buffer data.
 49. Thecomputer readable medium comprising instructions to implement a methodfor dynamically creating a process flow of claim 47, wherein theprovided data corresponds to alternate routing tables of the processflow or process definition methods.
 50. A computer readable mediumcomprising instructions executed by a computer system to implement amethod for dynamically creating a value stream map corresponding to aprocess flow, the value stream map represented by a plurality of valuestream metrics corresponding to a plurality of cells of the process andto interrelationships between the plurality of cells, the methodcomprising: triggering a state engine to simulate the process flow, thestate engine configured to manage operations rules related to theprocess flow; providing on the fly value metrics data to the stateengine, thereby dynamically incorporating the provided data todynamically create the value stream map.
 51. The computer readablemedium comprising instructions to implement a method for dynamicallycreating the value stream map of claim 50, wherein the provided data isprovided by external applications.
 52. The computer readable mediumcomprising instructions to implement a method for dynamically creatingthe value stream map of claim 50, wherein the provided data correspondsto cell and/or buffer data.
 53. The computer readable medium comprisinginstructions to implement a method for dynamically creating the valuestream map of claim 50, wherein the provided data corresponds toalternate routing tables of the process flow or process definitionmethods.